Isolated magnetostrictive buffered liquid level sensor

CROSS REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. application Ser. No. 11/766,386, filed Jun. 21, 2007 which is a continuation of U.S. Pat. No. 7,345,472, issued Mar. 18, 2008 which is a continuation of U.S. Pat. No. 6,612,168, issued Sep. 2, 2003 which is a continuation-in-part of U.S. Pat. No. 5,736,855, issued Apr. 7, 1998 which is a continuation-in-part of U.S. application Ser. No. 08/439,502 filed May 11, 1995.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to magnetostrictive displacement or distance measuring transducers, and more particularly to magnetostrictive transducers having modular construction including for displacement or distance measuring and adapted for easy configuration of assembly of field equipment after manufacture or assembly from stocked modules. This construction also facilitates modular construction of an explosion-proof field device.

2. Description of the Art

Magnetostrictive transducers having elongated waveguides that carry torsional strain waves induced in the waveguide when current pulses are applied along the waveguide through a magnetic field are well known in the art. A typical linear distance measuring device using a movable magnet that interacts with the waveguide when current pulses are provided along the waveguide is shown in U.S. Pat. No. 3,898,555.

Devices of the prior art of the sort shown in U.S. Pat. No. 3,898,555 also have the sensor element embedded into the protective housing which also houses the electronics to at least generate the pulse and provide certain mounting means associated with the device for the customer.

U.S. Pat. No. 5,313,160 teaches a modular design in which the sensor and electronic assembly can be removed from the application package. In the application package is the outer housing which is used by the customer for mounting an attachment of the sensor and electronics assembly with the end device whose position is to be measured. Sensor designs of the past have required delicate handling until the fabrication of the total unit, including the outer housing and electronics, has been completed. Prior art also utilizes difficult to produce and expensive methods to suspend the waveguide and to prevent the reflection of the desired sonic strain wave. Prior high performance waveguide suspension systems utilize thin elastomer spacer discs which are individually positioned along the entire length of the waveguide. Installation of the discs is a time consuming, usually manual, operation. The best performing damping devices in use utilize molded rubber elements with a central hole. These are difficult to mold and time consuming to apply.

The prior art has deficiencies in that the electronics are included within the waveguide suspension device and an expensive means for waveguide suspension is utilized. The prior art also has deficiencies by not having modular constroction and pre-assembled sensor elements. Further if different sizes are needed, the unit must be removed. But in the prior art, the sensor and the electronic package were not removable and interchangeable because of the application electronics being attached.

It is an object of the present invention to provide for an easy configuration or assembly of field equipment after manufacture or assembly from stocked modules, including modular construction of an explosion proof sensor.

It is a further object of the present invention to remotely locate the sensor from the electronics.

SUMMARY OF THE INVENTION

The present invention relates to a modularly constructed magnetostrictive transducer of the sort set out in U.S. application Ser. No. 08/500,004 filed Jul. 10, 1995, having a modular constructed magnetostrictive transducer, permitting a pre-assembled sensor element. A sensor cartridge which may be used as an explosion proof probe and which is environmentally protected and mechanically strong for direct use in process control applications is disclosed. The outer housing can be made from any weldable metal, and a sheet of teflon or other plastic can be added, if needed for chemical resistance. The pre-assembled sensor elements allow easy configuration or assembly of field equipment after manufacture or assembly of the sensor element. It also permits potting for environmental seal and explosion proof construction. The transducer would be then a rugged component, and may be equipped with threading to thread to another explosion proof housing which contains the mating electronics. For explosion proof configurations, the explosion proof material is anchored within the housing to be held in place when exposed to higher pressures.

DESCRIPTION OF THE DRAWINGS

For a further understanding of the nature and objects of the present invention, reference should be had to the following figures in which like parts are given like reference numerals, and wherein:

<figref idref="DRAWINGS">FIG. 1</figref> depicts a side elevated view of the complete sensing element assembly;

<figref idref="DRAWINGS">FIG. 2</figref><i>a </i>is a cross-sectional view of the sensing element assembly of the preferred embodiment of the present invention of <figref idref="DRAWINGS">FIG. 1</figref> taken along section lines <b>2</b>-<b>2</b> of <figref idref="DRAWINGS">FIG. 1</figref> showing a portion of the waveguide and surrounding sleeves showing the damping element at the end of the waveguide;

<figref idref="DRAWINGS">FIG. 2</figref><i>b </i>is the same cross-sectional view of <figref idref="DRAWINGS">FIG. 2</figref><i>a</i>, but showing a first alternative of using a tuning wire between the damping element and the waveguide;

<figref idref="DRAWINGS">FIG. 2</figref><i>c </i>is the same cross-sectional view as <figref idref="DRAWINGS">FIG. 2</figref><i>a</i>, but shows a second alternative of external tube crimped over the damping element;

<figref idref="DRAWINGS">FIG. 2</figref><i>d </i>is the same cross-sectional view of <figref idref="DRAWINGS">FIG. 2</figref><i>a</i>, but shows a third alternative of the return wire in a different position and with an external tube crimped over the damping element;

<figref idref="DRAWINGS">FIG. 3</figref> depicts an elevated end view of the housing which shows the connector;

<figref idref="DRAWINGS">FIG. 4</figref> is a cross-sectional view of the sensing element assembly of the preferred embodiment of the present invention of <figref idref="DRAWINGS">FIG. 1</figref> taken along section lines <b>4</b>-<b>4</b> of <figref idref="DRAWINGS">FIG. 1</figref> showing the cross-section of the housing and a portion of the waveguide and surrounding sleeves but not showing the damping mechanism;

<figref idref="DRAWINGS">FIG. 5</figref> is a plan view of the bracket of the preferred embodiment of the present invention;

<figref idref="DRAWINGS">FIG. 6</figref> is a plan view of the bracket cover of the preferred embodiment of the present invention;

<figref idref="DRAWINGS">FIG. 7</figref> is a first profile view of the bracket of the preferred embodiment of the present invention;

<figref idref="DRAWINGS">FIG. 8</figref> is a first profile view of the bracket cover of the preferred embodiment of the present invention;

<figref idref="DRAWINGS">FIG. 9</figref> is a second profile view of the bracket of the preferred embodiment of the present invention showing it juxtaposed with the bracket cover of the preferred embodiment of the present invention;

<figref idref="DRAWINGS">FIG. 10</figref> is a third profile view of the bracket of the preferred embodiment of the present invention showing the bracket cover juxtaposed;

<figref idref="DRAWINGS">FIG. 11</figref> is a view in profile of the end opposite to the end of <figref idref="DRAWINGS">FIGS. 9 and 10</figref> of the bracket of the preferred embodiment of the present invention showing the bracket cover juxtaposed to it;

<figref idref="DRAWINGS">FIG. 12</figref> is a different side view of the profile of the bracket of the preferred embodiment of the present invention;

<figref idref="DRAWINGS">FIG. 13</figref> illustrates a cross sectional view of a sensor assembly using the transducer of the preferred embodiment of the present invention;

<figref idref="DRAWINGS">FIG. 14</figref> illustrates a cross-sectional view of the sensing element assembly of an alternate embodiment of the present invention of <figref idref="DRAWINGS">FIG. 1</figref> taken along section lines <b>2</b>-<b>2</b> of <figref idref="DRAWINGS">FIG. 1</figref> showing a portion of the waveguide and surrounding partial sleeves and showing the damping element at the end of the waveguide;

<figref idref="DRAWINGS">FIG. 15</figref> is an elevated view of the sensor cartridge of the preferred embodiment of the present invention;

<figref idref="DRAWINGS">FIG. 16</figref> is a partial sectional view of a portion of <figref idref="DRAWINGS">FIG. 15</figref>, showing the modularly constructed pre-assembled sensing element amid the potting; and

<figref idref="DRAWINGS">FIG. 17</figref> is a side view, partly in phantom line, of the isolator/potting plug of the preferred embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

A transducer or sensing element assembly of the type disclosed in U.S. application Ser. No. 08/500,004, filed Jul. 10, 1995, the disclosure of which is partially repeated below, or any other modular transducer that may be introduced in the future for purposes of permitting the production of easily assembled field equipment including explosion proof transducers, is shown indicated at <b>25</b> in <figref idref="DRAWINGS">FIG. 16</figref>. Transducer <b>25</b> is preassembled as a sensing element and may be used for measuring displacements and/or distances or other measurements, and the field assembled device of the present invention will be applicable to any of them. The type of transducer that may be used for the present invention should not be considered to be limited by the type of modular construction for pre-assembly use with the probe, including the preferred embodiment described below. The transducer and assembled sensor element should not be deemed to be limited to any particular type of electronics used with the waveguide. Additionally, the general type and nature of a transducer in electrically producing the return pulse and interfacing through the return pulse with any electronics of a buyer or user of the device, except that it be pre-assembled, should not be deemed to be limited by the disclosure.

The type of transducer that may be used for the present invention, should not be considered to be limited by the disclosure of the damping element used with the transducer. Further, except for mechanical construction indicating a preferred mechanical mounting of the waveguide, the general type of transducer should not be deemed to be limited by the disclosure of the waveguide suspension. The transducer should not be deemed to be limited to any particular type of electronics used with the waveguide except for the local buffer circuit. Additionally, the general type and nature of a transducer in electrically producing the return pulse and interfacing through the return pulse with any electronics of a buyer or user of the device should not be deemed to be limited by the disclosure except for the mechanical construction shown for the preferred embodiment and the printed circuit board containing the local buffer circuit.

The transducer <b>25</b> includes an elongated waveguide assembly enclosed in an enclosure tube <b>3</b>. Enclosure tube <b>3</b> and the waveguide assembly are mechanically supported at one end by a housing <b>17</b> through an end flange <b>19</b>. The waveguide assembly includes the outer enclosure tube <b>3</b> surrounding a coaxial elongated interior waveguide <b>4</b> (<figref idref="DRAWINGS">FIG. 2</figref>). Whenever “FIG. <b>2</b>” is referenced in this specification, it means any of the embodiments of <figref idref="DRAWINGS">FIGS. 2</figref><i>a</i>-<b>2</b><i>d</i>. A current is passed through the waveguide <b>4</b> and returns through a return wire <b>1</b> electrically connected to the waveguide <b>4</b>. Typically, a magnet (not shown) is mounted over the waveguide assembly and enclosure tube <b>3</b> by being placed over and coaxial with enclosure tube <b>3</b>. The magnet interacts with the current pulse as more completely described in U.S. Pat. No. 3,898,555. Upon the strain wave pulse returning to the housing <b>17</b> after passing through the waveguide <b>4</b> and return wire <b>1</b>, the placement of waveguide <b>4</b> and return wire <b>1</b> being more completely described below, a suitable mode converter (partially shown) of any type known or to be known in the art provides an electrical signal through connector <b>21</b> to any electronic circuit connected to it, such as electronic circuit <b>26</b>.

The structure of the circuit <b>26</b> is dependent on the use of transducer <b>25</b>, and will work with the waveguide suspension sleeve <b>2</b> and modular construction elements of the present invention despite disparities in structure. The structure of circuit <b>26</b> should not be considered as limiting the invention. Thus, no particular mechanism for the arrangement of the element <b>26</b> or any conditioning of the signal to circuit <b>26</b> is shown to be preferred to emphasize generality. Further, it should be understood that the waveguide suspension sleeve <b>2</b> mechanism of the present invention is applicable to any transducer <b>25</b> and waveguide <b>4</b> of the type for measuring displacement and/or distance and/or other measurement using the magnetostrictive principles, such as generally shown in U.S. Pat. No. 3,898,555, but is dependent for modular assembly to some extent on the mechanical arrangement of elements in housing <b>17</b>. Thus, for example, a particular mechanism for a preference for the arrangement of the elements in the housing <b>17</b> is shown to be preferred for mounting, but otherwise should not limit generality. The mechanism other than mounting may be of any sort, including such as those shown in U.S. Pat. No. 3,898,555 or others known in the art or still to be thought of in the art or that are in design in the art. For this same reason, the type of magnet used and the type of application used is also not shown, and may be any application. Finally, because there is some need to show the interaction between the damping element <b>6</b> (<figref idref="DRAWINGS">FIG. 2</figref>) and the waveguide suspension sleeve <b>2</b> and other portions of transducer <b>25</b> at the remote portion of the waveguide assembly, a preferred embodiment for an enclosure tube <b>3</b> (<figref idref="DRAWINGS">FIG. 2</figref>), discussed below, with the waveguide suspension sleeve <b>2</b> and damping element <b>6</b> is shown. This should not be considered as limiting but only illustrative, the waveguide suspension sleeve <b>2</b> being capable of use with any type of waveguide assembly as set out above.

The remote end portion of enclosure tube <b>3</b>, remote from housing <b>17</b>, is shown in cross-section in <figref idref="DRAWINGS">FIG. 2</figref> and ends with an end plug <b>20</b>. An inert gas maybe introduced in enclosure tube <b>3</b> to further promote isolation and sealing. End plug <b>20</b> acts to stop fluid and other materials from entering enclosure tube <b>3</b>. The end of the waveguide assembly having end plug <b>20</b>, is normally the end which would be at the bottom of a tank, if transducer <b>25</b> is being used for determining the level of liquid in a tank, or at the end of the displacement if the transducer <b>25</b> were used to measure distance. As discussed in the Background, it is desired to make the dead zone, or non-signal producing zone, adjacent to the end plug <b>20</b> as short as possible and yet accomplish the purpose of dampening the sonic strain wave signal to prevent reflected strain waves from interfering with the desired return strain wave signal that represents distance or level, such as discussed in U.S. Pat. No. 3,898,555.

As shown in <figref idref="DRAWINGS">FIG. 2</figref>, a waveguide <b>4</b> is enclosed through concentrically layered enclosure mechanisms, including a suspension sleeve <b>2</b> and enclosure tube <b>3</b>. The suspension sleeve <b>2</b> comprises a tubular braided sleeve, or elastomer sleeve, or composite sleeve, of a geometry having the characteristics of restricting the lateral movement of the waveguide <b>4</b> and insulating the waveguide <b>4</b> from vibration and external sonic noise yet not contacting the waveguide <b>4</b> so much as to damp the sonic strain wave signal generated by the interaction of the electric current and external magnet. Suspension sleeve <b>2</b> is coaxial with and surrounds the waveguide <b>4</b> for substantially its entire length, or at least a major portion thereof. Suspension sleeve <b>2</b> is shown mounted within and coaxial for substantially the entire length of waveguide <b>4</b>, or at least a major portion thereof, with outer enclosure tube <b>3</b>.

The inner diameter of the suspension sleeve <b>2</b> must be small enough to limit the movement of the waveguide <b>4</b> yet large enough so that it does not hold, grab, constrict or otherwise compress the waveguide <b>4</b>. If suspension sleeve <b>2</b> compresses, holds, grabs or constricts the waveguide <b>4</b>, attenuation of the sonic strain wave signal along waveguide <b>4</b> will occur. The Wiedemann Effect does not promote a large sonic strain wave signal in the prior art, making it difficult to differentiate it from noise produced by other mechanisms. Accordingly, signal attenuation is known in the prior art to be a phenomenon to be avoided.

The outer diameter of suspension sleeve <b>2</b> must be large enough to restrict lateral movement of suspension sleeve <b>2</b> within enclosure tube <b>3</b>, yet small enough to fit easily within the inner diameter of the enclosure tube <b>3</b>, together with the return wire <b>1</b> as will be discussed below. Also, it may be possible to have the suspension sleeve <b>2</b> present without requiring the restriction of an enclosure tube <b>3</b>, and the use of an enclosure tube <b>3</b> should not be considered limiting to the invention or even to the waveguide suspension. Overall, the waveguide <b>4</b> must be suspended in a manner that cushions it from shock and vibration stimuli so that associated erroneous responses are eliminated.

Suspension sleeve <b>2</b> includes an inner layer <b>27</b> and an outer layer <b>29</b>. The fiber that makes up inner layer <b>27</b> of suspension sleeve <b>2</b> is non conducting and may be a fine, hard material, or a combination of materials such as ceramic or glass or metal or polymer. The strand count and weave configuration of such fiber are typically from eight to sixteen strands in diamond, regular, hercules or other weave pattern. Such strand, count and weave configuration enable the suspension sleeve <b>2</b> to act as a cushion between the waveguide <b>4</b> and the enclosure tube <b>3</b>. Interior to the inner layer <b>27</b> and exterior to the waveguide <b>4</b>, there is clearance <b>28</b> such that the inner layer <b>27</b> is loosely fitting around waveguide <b>4</b>. The outer layer <b>29</b> of suspension sleeve <b>2</b> helps to maintain the shape of the inner layer <b>27</b>, and isolate it from the enclosure tube <b>3</b>. The outer layer <b>29</b> is typically a softer material, such as a silicone rubber and is a second layer of inner layer <b>27</b>.

Suspension sleeve <b>2</b> ends at its remote side at end <b>31</b> facing toward the end plug <b>20</b>. Juxtaposed with the end <b>31</b> of the suspension sleeve <b>2</b> is damping element <b>6</b>. Damping element <b>6</b> is Slipped over the end of the waveguide <b>4</b> and is coaxial with waveguide <b>4</b> and generally cylindrical in shape, as is suspension sleeve <b>2</b>. However, the damping element <b>6</b> is not loose fitting over the waveguide <b>4</b>, but is more constrictive over waveguide <b>4</b> in order to provide damping. Thus, as shown in <figref idref="DRAWINGS">FIGS. 2</figref><i>a </i>and <b>2</b><i>b</i>, the inner layer <b>27</b> of damping element <b>6</b> snugly fits about waveguide <b>4</b>. Further, the outer layer <b>29</b> of damping element <b>6</b> while usually of softer elastomer materials, such as silicone rubber, does not normally contact enclosure tube <b>3</b>, as does outer layer <b>29</b> of suspension sleeve <b>2</b>, but instead is sized to control the amount of and to exert pressure on the inner layer <b>27</b> which in turn exerts pressure on the waveguide <b>4</b>. Thus, a space is left between the outer layer <b>29</b> of damping element <b>6</b> and the inner surface of enclosure tube <b>3</b>.

In addition, a tuning wire <b>5</b> (see <figref idref="DRAWINGS">FIG. 2</figref><i>b</i>) of a diameter ranging from 0.005 inches to 0.016 inches may be used to act as a wedge, thereby controlling the pressure of inner layer <b>27</b> on the waveguide <b>4</b>. The tuning wire <b>5</b> is adjacent to waveguide <b>4</b> and extends substantially along and is enclosed by inner layer <b>27</b> of damping element <b>6</b>. It is used to change the acoustic impedance of the damping element <b>6</b> but to do so gradually so that the sonic strain wave signal is dampened gradually along the distance of the waveguide <b>4</b> enclosed by damping element <b>6</b>. In this way, no reflection will occur from sudden changes in impedance, but instead damping of the sonic strain wave amplitude along the damping element <b>6</b> will occur. It should be noted that the tuning wire <b>5</b> while only shown in <figref idref="DRAWINGS">FIG. 2</figref><i>b </i>may be used with any of the configurations of <figref idref="DRAWINGS">FIGS. 2</figref><i>a</i>-<b>2</b><i>d </i>and may be used in any other kind of damping element for the purposes set out above.

Further, because damping element <b>6</b> is used to provide optimum damping of the sonic strain wave pulse traveling in the waveguide <b>4</b>, and because proper acoustic matching of the waveguide <b>4</b> and the damping element <b>6</b> is determined by the pressure exerted on the waveguide <b>4</b> by the inner layer <b>27</b>, there are other mechanisms besides the tuning wire <b>5</b> that can be used. As shown in <figref idref="DRAWINGS">FIGS. 2</figref><i>c </i>and <b>2</b><i>d</i>, a damping element <b>6</b> for use over a broad temperature range could be used, comprising a short braided sleeve <b>8</b> of the sort of inner layer <b>27</b>, but with such braided sleeve <b>8</b> inserted into a coaxial, larger diameter metal sleeve <b>9</b>. This assembly of sleeves <b>8</b>, <b>9</b> is slipped onto the end of the waveguide <b>4</b>. The metal sleeve <b>9</b> may then be crimped such that the braided sleeve <b>8</b> contacts the waveguide <b>4</b> with sufficient pressure to provide the required damping action.

Thus, as seen through <figref idref="DRAWINGS">FIGS. 2</figref><i>a</i>-<b>2</b><i>d</i>, damping may occur through the pressure of outer layer <b>29</b> or through the tuning wire <b>5</b> trapped in inner layer <b>27</b> or through the crimping of metal sleeve <b>9</b> or by any other mechanism that applies the appropriate pressure to control the impedance matching along a predetermined length of the damping element <b>6</b> as determined by experiment.

The end <b>32</b> of damping element <b>6</b> facing end <b>31</b> of suspension sleeve <b>2</b> is preferably cut between a 40° and 50° angle and preferably about a 45° angle in order to properly match its impedance at that of the waveguide <b>4</b>.

An additional way to minimize end reflections from the damping element <b>6</b> is to place another damping sleeve <b>33</b> of dissimilar material or size or pressure in front of damping element <b>6</b> (toward the suspension sleeve <b>2</b>). Damping sleeve <b>33</b> should be designed to have a closer acoustic impedance match to the waveguide <b>4</b>. That is, it should have less pressure, or smaller outer diameter, or lower mass density than damping element <b>6</b>, or if it is an elastomer, it should have a low durometer, such that the front end reflection is minimized. Damping sleeve <b>33</b> includes a face <b>34</b> facing toward face <b>32</b> of damping element <b>6</b>. Face <b>34</b> normally has a plane substantially perpendicular to the longitudinal axis of the waveguide <b>4</b>. It should be noted that damping sleeve <b>33</b> may be used with any of the damping elements <b>6</b> of <figref idref="DRAWINGS">FIGS. 2</figref><i>a</i>, <b>2</b><i>b</i>, <b>2</b><i>c </i>and <b>2</b><i>d</i>, and the depiction showing it only in <figref idref="DRAWINGS">FIG. 2</figref><i>a </i>should not limit its generality. Further, the orientation of face <b>34</b> will not change if damping sleeve <b>33</b> is used with the damping sleeves <b>6</b> of <figref idref="DRAWINGS">FIG. 2</figref><i>b</i>, <b>2</b><i>c </i>or <b>2</b><i>d</i>, each of which has a slanted face <b>32</b>. The face <b>34</b> will continue to have a plane substantially perpendicular to the longitudinal axis of the waveguide <b>4</b>. Generally, this damping sleeve <b>33</b> does not damp as efficiently as the damping element <b>6</b>, but it will damp the reflection from the damping element <b>6</b>, thereby lowering the overall sonic energy leaving the damping system, damping element <b>6</b> acting as the primary damp and damping sleeve <b>33</b> acting as a secondary damp.

Still another method of minimizing the front end reflection coming from the damping element <b>6</b> is to expand the inside diameter of the damping element <b>6</b> at the front end. The end facing suspension sleeve <b>2</b>. This can be accomplished by inserting a flaring tool in such front end of the damping element <b>6</b> just prior to placing it on the waveguide <b>4</b>.

Still another method for minimizing the front end reflection coming from damping element <b>6</b> is to remove material from the outside diameter on such front end of damping element <b>6</b>. This removal region should be in the range of 0.125″ to 0.5″ as measured from such front end of damping element <b>6</b>. This can be accomplished, for example, by using a set of wire strippers to remove part of the elastomer that overlaps the braid.

The return wire <b>1</b> must pass over damping element <b>6</b> as shown in <figref idref="DRAWINGS">FIGS. 2</figref><i>a</i>, <b>2</b><i>b </i>and <b>2</b><i>d</i>, or through damping element <b>6</b> as in <figref idref="DRAWINGS">FIG. 2</figref><i>c</i>. In <figref idref="DRAWINGS">FIG. 2</figref><i>c</i>, the return wire <b>1</b> is insulated (as it may be in all other cases) and can also act in a manner similar to the tuning wire <b>5</b> of <figref idref="DRAWINGS">FIG. 2</figref><i>b</i>. In all events, the return wire <b>1</b> must then be attached to the tip of the waveguide <b>4</b> using solder or a crimp ring <b>7</b>, and must be electrically connected to form the rest of the circuit to support the current pulse which begins in housing <b>17</b> and flows through waveguide <b>4</b> to return through return wire <b>1</b>, which may be arranged as discussed in U.S. Pat. No. 3,898,555 or any other way known or to be known in the art.

The pressure applied by the inner layer <b>27</b> may be substantially uniform, but may also be nonuniform with less pressure on the side facing the housing <b>17</b> and more pressure on the side facing the end plug <b>20</b> to shorten the length of the damping element <b>6</b> for a given damping effectiveness while preventing reflection.

Alternately, the return wire <b>1</b> may be braided into suspension sleeve <b>2</b> or enclosure tube <b>3</b> may be conductive and the return wire <b>1</b> may be connected electrically to enclosure tube <b>3</b>. Otherwise, in assembly, the return wire <b>1</b> and suspension sleeve <b>2</b> are inserted into enclosure tube <b>3</b>. The waveguide <b>4</b> is then pulled into the suspension sleeve <b>2</b> because suspension sleeve <b>2</b> is sized such that the waveguide <b>4</b> is in loose contact with it but does not allow excessive lateral movement. Further, the damping element <b>6</b> is then slipped over the waveguide <b>4</b>.

Further, a series of short suspension sleeves <b>2</b> may be located along the length of waveguide <b>4</b>, instead of a single continuous suspension sleeve <b>2</b>, as shown in <figref idref="DRAWINGS">FIG. 14</figref>, although this is an alternate embodiment and believed to be more difficult to construct. In such a series, care should be taken in the spacing to decouple or otherwise suppress external or internal mechanical noise.

Return wire <b>1</b>, suspension sleeve <b>2</b>, enclosure tube <b>3</b> and waveguide <b>4</b> are supported in housing <b>17</b> by a bracket <b>10</b> (<figref idref="DRAWINGS">FIG. 4</figref>) preferably made of plastic. The details of the bracket <b>10</b> are shown in <figref idref="DRAWINGS">FIGS. 5-12</figref>. Bracket <b>10</b> includes a base <b>60</b>, the outer diameter of base <b>60</b> being substantially equal to the inner diameter of the main enclosure <b>62</b> of housing <b>17</b>. Base <b>60</b> includes two flanges <b>64</b>, <b>66</b> located on either side of a recess portion <b>68</b> of base <b>60</b>. This arrangement permits a groove <b>70</b> (<figref idref="DRAWINGS">FIG. 4</figref>) to be present between the two flanges <b>64</b>, <b>66</b>. A seal ring <b>16</b> is located inside groove <b>70</b> sealingly engaging the sidewalls <b>72</b>, <b>74</b> of flanges <b>64</b>, <b>66</b>, respectively, and the outward facing wall <b>76</b> of recess <b>68</b>, as shown in <figref idref="DRAWINGS">FIG. 4</figref>. As used above, the word “diameter” does not imply a circular shape. As best seen in <figref idref="DRAWINGS">FIG. 4</figref> and from the shape of flanges <b>64</b>, <b>66</b>, the interior <b>62</b> of housing <b>17</b> is more rectangular in shape with two curved opposing sides. Thus, with the shape and sizing of flanges <b>64</b>, <b>66</b>, seal ring <b>16</b> also contacts the interior sidewall surface <b>78</b> of the main enclosure <b>62</b> of housing <b>17</b>. Therefore, seal ring <b>16</b> acts to seal wiring and connectors interior in housing <b>17</b> to surface <b>80</b> of flange <b>66</b> (<figref idref="DRAWINGS">FIG. 4</figref> and <figref idref="DRAWINGS">FIG. 9</figref>).

The end of housing <b>17</b> is closed by flange <b>19</b>. An opening <b>82</b> is formed in flange <b>19</b> and sized to permit enclosure tube <b>3</b> to snugly fit through opening <b>82</b> and extend into an opening <b>84</b> formed in flanges <b>64</b>,<b>66</b> and recess portion <b>68</b> of base <b>60</b> which is coaxial with opening <b>82</b> and of the same size as opening <b>82</b>. Base <b>60</b> also includes a second opening <b>86</b> formed adjacent to flange <b>66</b> and coaxial with opening <b>84</b> but of smaller diameter than opening <b>84</b>, thereby forming a shoulder <b>88</b> between openings <b>84</b>, <b>86</b> against which abuts end <b>90</b> of the combination of suspension sleeve <b>2</b> and enclosure tube <b>3</b>.

Bracket <b>10</b> further includes an extension <b>91</b> that extends beyond base <b>60</b> toward the end surface <b>92</b> of enclosure or housing <b>17</b>. Extension <b>91</b> includes an intermediate opening <b>94</b> spaced Between opening <b>86</b> and the end surface <b>96</b> of bracket <b>10</b> and end <b>98</b> of bracket <b>10</b>. Opening <b>94</b> is coaxial with openings <b>84</b>, <b>86</b>. Opening <b>94</b> is also partially formed by bracket cover <b>14</b> (<figref idref="DRAWINGS">FIG. 8</figref>). In forming such opening <b>94</b>, a lateral opening <b>100</b> is formed by the clearance between bracket <b>10</b> and a notch <b>61</b> in bracket cover <b>14</b>. Opening <b>100</b> connects the interior between opening <b>94</b> and opening <b>86</b> with a channel <b>30</b>, formed in bracket cover <b>14</b>.

With the combination of suspension sleeve <b>2</b> and enclosure tube <b>3</b> abutting or otherwise terminating at shoulder <b>88</b>, both the return wire <b>1</b> and the waveguide <b>4</b> extend from end <b>90</b> into the space interior to housing <b>17</b>. Return wire <b>1</b> is caused to pass through opening <b>100</b> and into channel <b>30</b> with a specific alignment described below. Waveguide <b>4</b> continues coaxial with opening <b>94</b> and is anchored by a waveguide anchor <b>11</b>, preferably made of brass. Waveguide anchor <b>11</b> has a cylindrical shaped lower end <b>101</b> of diameter sufficient to fit into opening <b>94</b>. A larger substantially rectangular cap <b>103</b> forms the top of waveguide anchor <b>11</b> with shoulder <b>105</b> formed therebetween. Shoulder <b>105</b> rests on surfaces <b>102</b>, <b>104</b> which form the upper or inner facing surface of opening <b>94</b>. Another opening <b>55</b> is provided in extension <b>91</b> whose axis is at right angles to the axis of openings <b>84</b>,<b>86</b>,<b>94</b> (<figref idref="DRAWINGS">FIG. 10</figref>). The identical opening <b>55</b> is formed in the other side of the extension <b>91</b> as shown in <figref idref="DRAWINGS">FIG. 7</figref>. The waveguide anchor <b>11</b> is sized such that in its seated position with surface <b>105</b> in contact with surfaces <b>102</b>, <b>104</b>, anchor <b>11</b> does not extend over opening <b>55</b>. Waveguide anchor <b>11</b> further includes a central opening <b>106</b> coaxial with the axis of suspension sleeve <b>2</b> and waveguide <b>4</b>. Opening <b>106</b> is sized to permit the insertion of waveguide <b>4</b> through it.

Cylindrical shaped elements <b>108</b>, <b>110</b> extend from surface <b>98</b> and face toward the end <b>92</b> of housing <b>17</b>. The upper surface <b>114</b> of cylindrical member <b>110</b> is substantially coplaner with the end surfaces <b>96</b> and act as supports for a printed circuit board <b>12</b> mounted near end <b>92</b>. Cylindrical shaped elements <b>108</b> extend from surfaces <b>96</b> and engage reciprocally located features (not shown) in circuit board <b>12</b> to locate and align circuit board <b>12</b>. Printed circuit board <b>12</b> is equipped with a series of openings <b>116</b>, <b>118</b> and two not shown to permit return wire <b>1</b> to pass through opening <b>116</b> and waveguide <b>4</b> to pass through opening <b>118</b> and two additional leads from a pickup coil <b>13</b> yet to be discussed. In addition, printed circuit board <b>12</b> has openings <b>120</b> that permit leads <b>50</b> to pass from connector <b>21</b> through printed circuit board <b>12</b>. Thus, return wire <b>1</b>, waveguide <b>4</b>, a dummy lead <b>50</b> and leads <b>35</b> of pickup coil <b>13</b> (yet to be discussed) all pass through printed circuit board <b>12</b> and are electrically connected by printed circuit board <b>12</b> with electrical connector <b>21</b> as five leads <b>50</b> (<figref idref="DRAWINGS">FIG. 3</figref>). Connector <b>21</b> physically rests on printed circuit board <b>12</b> and extends from it through an opening <b>122</b> formed in the end <b>92</b> of housing <b>17</b> to make connector <b>21</b> available to customers or users as shown in <figref idref="DRAWINGS">FIG. 3</figref>. Housing <b>17</b> is closed by flange <b>19</b> which may also include extensions <b>124</b> having openings <b>126</b> therethrough for mounting housing <b>17</b> in the customer's or user's device.

As shown in <figref idref="DRAWINGS">FIG. 7</figref>, two additional openings <b>128</b>, <b>130</b> are included in extension <b>91</b> of bracket <b>10</b>. The axis of each opening <b>128</b>, <b>130</b> is perpendicular to the axis of the other openings discussed above. Opening <b>128</b> is larger than opening <b>130</b> and is sized to admit a pickup coil <b>13</b> (<figref idref="DRAWINGS">FIG. 4</figref>). Pickup coil <b>13</b> may be any type coil and is shown preferably with a high wire winding count but may be of any design without limiting the generality of the invention. The pickup coil <b>13</b> is shown in <figref idref="DRAWINGS">FIG. 4</figref> as having copper windings <b>40</b> mounted on a bobbin base <b>45</b>. Two leads <b>35</b> extend from pickup coil <b>13</b> through printed circuit board <b>12</b> where they are electrically connected as discussed above. Pickup coil <b>13</b> is mounted coaxially about a tape <b>15</b> reciprocally mounted in an opening <b>132</b> in pickup coil <b>13</b>. Tape <b>15</b> extends from substantially the end of bobbin <b>45</b> facing outward towards housing <b>17</b> through the pickup coil <b>13</b> and to the waveguide <b>4</b> where it is connected to waveguide <b>4</b> by welding or other method of mechanical connection. Tape <b>15</b> does extend for a length <b>15</b>′ beyond the end of the bobbin <b>45</b>. This length <b>15</b>′ provides constructive interference to the signal. The signal is developed as a voltage across the coil <b>13</b>. The constructive interference is produced by the sonic wave continuing past the coil <b>13</b>, reflecting from the end of tape <b>15</b>, including all of the length <b>15</b>′ and arriving back at coil <b>13</b> with such time delay as to produce an additive effect. This causes constructive interference for any type of tape <b>15</b> or circuitry with respect to the coil <b>13</b>. An anchor or bracket for the end of tape <b>15</b> could alternately be used to set the length <b>15</b>′. Tape <b>15</b> is typically made of a ferromagnetic or magnetostrictive material and may be of the same material as the waveguide <b>4</b> but have a different metallurgical treatment. Opening <b>128</b> is thus located in close proximity to channel <b>30</b> to place the pickup coil <b>13</b> in close proximity to return wire <b>1</b>, thereby permitting a reduction in energy of the input pulse to waveguide <b>4</b>.

Opening <b>130</b> is sized to receive a bias magnet <b>18</b> or unmagnetized magnet material which could be installed for later magnetization during the assembly process.

For assembly of the waveguide assembly into housing <b>17</b>, the waveguide <b>4</b> is placed into the waveguide anchor <b>11</b> after suspension sleeve <b>2</b>, waveguide <b>4</b> and enclosure tube <b>3</b> had been inserted into the openings <b>82</b>,<b>84</b> of flange <b>19</b> and bracket <b>10</b>. After the waveguide <b>4</b> is inserted into anchor <b>11</b>, it is connected to the printed circuit board <b>12</b>. The suspension sleeve <b>2</b> and enclosure tube <b>3</b> are held in place in the bracket <b>10</b> with adhesive or by suitable retaining elements not shown.

After the waveguide <b>4</b> is placed into the brass waveguide anchor <b>11</b> and connected to the printed circuit board <b>12</b>, the pickup coil <b>13</b> is added. The return wire <b>1</b> is held in place while the bracket cover <b>14</b> is installed and then the tape <b>15</b> is welded or otherwise mechanically connected onto the waveguide <b>4</b> using openings <b>55</b>. It is not necessary to attach the tape in the sequence set out above and the sequence should not be considered as limiting fur all the inventions disclosed. The bias magnet <b>18</b> is then installed, or as indicated above unmagnetized magnetic material could have been installed earlier and then magnetized. Finally seal ring <b>16</b> is placed into groove <b>70</b> of bracket <b>10</b>. Thereafter, the bracket <b>10</b> and the waveguide <b>4</b> and the flange <b>19</b> (if the flange <b>19</b> is used) as an assembly is inserted into the housing <b>17</b>. The housing <b>17</b> is crimped and/or welded in place. Finally, the air inside the device is displaced by a dry, unreactive gas, and the end plug <b>20</b> is held in place with adhesive or other means.

The distance and location of return wire <b>1</b> with respect to waveguide <b>4</b> can be adjusted in any appropriate manner to permit the magnetic fields induced in these two wires to cancel each other. In addition, by properly routing return wire <b>1</b> in the area immediately adjacent the pick up coil <b>13</b>, the ringing of the interrogation pulse can be reduced significantly, such as fifty percent or more. The size and magnetic properties, such as using copper of the sizes set out above for tuning wire <b>5</b> also have an effect on the ringing.

Transducer <b>25</b> is produced in one inch incremental lengths or some other incremental length on the order of one-half inch to four inches. This is done to reduce the total number of unique lengths to which waveguide <b>4</b>, suspension sleeve <b>2</b>, return wire <b>1</b>, and enclosure tube <b>3</b> must be cut. This reduces the cost and complexity of manufacturing transducer <b>25</b>, yielding a more cost effective product. Complete sensor assemblies which utilize transducer <b>25</b> can be manufactured in any length or incremental length desired. This is accomplished by providing a mounting means for transducer <b>25</b> within the complete sensor assembly which allows transducer <b>25</b> to be positioned axially at any point within ±½ inch of its median position within the complete sensor assembly. A transducer <b>25</b>, the length of which is within ±½ inch of the length desired for the complete sensor assembly, can thus be positioned within the complete sensor assembly to provide precisely the sensing length desired.

<figref idref="DRAWINGS">FIG. 13</figref> illustrates one possible implementation of the mounting means for using transducer <b>25</b> in one inch incremental lengths (or some other incremental length on the order of one-half inch to four inches) to produce sensor assemblies <b>158</b> in any length desired. Sensor assembly <b>158</b> includes an application housing <b>150</b> having an end cap <b>155</b>. Transducer <b>25</b> is secured to application housing <b>150</b> using screw fasteners <b>152</b> passing through openings <b>126</b> of extensions <b>124</b> of mounting housing <b>17</b> or other suitable attachment means. When necessary to achieve a proper fit, a spacer block <b>151</b> may be positioned between transducer <b>25</b> and application housing <b>150</b>. Spacer block <b>151</b> is utilized in a variety of thicknesses or is not used at all depending on the sensing length required of sensor assembly <b>158</b> and the standard length of the enclosure tube <b>3</b> containing waveguide <b>4</b> supplied as part of transducer <b>25</b>. Fasteners <b>152</b> are also used in a variety of lengths to correspond to the thickness of spacer block <b>151</b>. Transducer <b>25</b> is shown in <figref idref="DRAWINGS">FIG. 13</figref> in the middle of the range of movement possible within endcap <b>155</b>. Wire harness <b>156</b> carries signals and supply voltages between transducer <b>25</b> and customer or vendor supplied electronic circuit board <b>157</b>. Wire harness <b>156</b> is of sufficient length and flexibility to allow transducer <b>25</b> to be secured anywhere within the allowed range of positions after being connected to electrical connector <b>21</b>. Electronic circuit board <b>157</b> (<figref idref="DRAWINGS">FIG. 13</figref>) provides the interrogation and signal conditioning circuitry, as known in the art, necessary to communicate with the end user system and to provide the desired position feedback signals. A wire harness <b>153</b> is connected to the electronic circuit board <b>157</b> (<figref idref="DRAWINGS">FIG. 13</figref>) and carries signals and supply voltages between electronic circuit board <b>157</b> (<figref idref="DRAWINGS">FIG. 13</figref>) and an external connector <b>154</b> attached to endcap <b>155</b>. External connector <b>154</b> provides the physical means for connecting to the end user system (not shown).

All of the features of a particular preferred embodiment of the waveguide assembly are not shown in the above disclosure in order to emphasize the generality of the disclosure. For example, a buffer circuit may be used to prevent coil saturation of pickup coil <b>13</b> when the pulse is initially introduced along waveguide <b>4</b>. Such a circuit would help more closely couple the tape <b>15</b> and coil <b>13</b> to the waveguide <b>4</b>.

Further, the transducer disclosed in this application may be fully electrically isolated or shielded including electrically shielded by housing <b>17</b> from all devices in which it is mounted by having mounting or spacer block <b>151</b> and screw fasteners <b>152</b> made of nonconducting material and having an insulating material <b>200</b> between tube <b>3</b> and external extension tube <b>202</b>.

The transducer <b>25</b> assembled as a sensor element is enclosed in a sensor cartridge <b>350</b> which is an application package as an installable unit and includes an elongated waveguide assembly. Because of the modular nature of the assembled transducer <b>25</b>, the sensor element <b>25</b> may have interchanging with various electronic assemblies, and can be used in or as an explosion proof housing. The waveguide assembly is enclosed in an enclosure tube <b>3</b> which passes through a cylindrical opening <b>370</b> formed by walls <b>371</b> of isolator/plug <b>310</b>. Walls <b>371</b> are enclosed by an opening <b>375</b> formed in a thick front end section <b>340</b> of cartridge <b>350</b>.

Enclosure tube <b>3</b> is enclosed in a sheath <b>300</b> inserted into an opening <b>360</b> of front end section <b>340</b> which abuts and is coaxial with opening <b>375</b>. Front end section <b>340</b> is thick to permit adequate alignment of sheath <b>300</b> and ease of welding. An RTD (not shown) may also be enclosed by enclosure tube <b>3</b> from which RTD wires <b>320</b> extend from such RTD. Enclosure tube <b>3</b> and the waveguide assembly are mechanically supported at one end by a housing <b>17</b> mechanically connected to the waveguide assembly which, as set out above, is supported by tube <b>3</b> extending through the end of isolator/plug <b>310</b> which abuts the end surface of housing <b>17</b>. Opening <b>370</b> is sized to permit enclosure tube <b>3</b> to snugly fit through the opening <b>370</b>. Isolator/plug <b>310</b> is not attached to thick front end section <b>340</b> but merely has walls <b>371</b> inserted into opening <b>375</b>. End <b>372</b> of isolator/plug <b>310</b> abuts interior end wall <b>335</b> of thick front end section <b>340</b>. If potting material is used for explosion proof applications, the potting material, as discussed below, will hold the isolator/plug <b>310</b> in place. Otherwise, isolator/plug <b>310</b> would be attached to <b>340</b>.

The waveguide assembly includes the outer enclosure tube <b>3</b> surrounding a coaxial elongated interior waveguide. Typically, a magnet (not shown) is mounted on the sheath <b>300</b> by being placed over and coaxial with sheath <b>300</b>. The magnet interacts with a current pulse as more completely described in U.S. Pat. No. 3,898,555. The type of magnet used and the type of application used is not shown, and may be any application.

The end portion of enclosure tube <b>3</b>, that is remote from housing <b>17</b>, is shown in cross-section in <figref idref="DRAWINGS">FIG. 16</figref> and ends with an end plug (not shown). Sheath <b>300</b> extends beyond the end of enclosure tube <b>3</b> and ends with an end plug <b>330</b>. An inert gas may be introduced in enclosure tube <b>3</b> to further promote isolation and sealing. End plug <b>330</b> acts to stop fluid and other materials from entering enclosure tube <b>3</b>.

Enclosure or housing <b>17</b> is located in a cylindrical opening in the interior of sensor cartridge <b>350</b>. Opening <b>380</b> extends interiorly from interior wall <b>335</b> to opposing end <b>381</b>. Enclosure <b>17</b> extends into interior <b>380</b> from the interior facing wall <b>382</b> of isolator/potting plug <b>310</b> to the interior face <b>381</b> of threaded end <b>420</b> of sensor cartridge <b>350</b> which contains exit conduit or cable jacket <b>390</b>. RTD wires <b>320</b> extend from isolator/potting plug <b>310</b> through the interior <b>380</b> of sensor cartridge <b>350</b> and through exit conduit oer cable jacket <b>390</b>. Conductors <b>156</b> extend from housing <b>17</b> through the interior <b>380</b> of sensor cartridge <b>350</b> and through exit conduit <b>390</b>. Exit conduit <b>390</b> may include, and for explosion proof installations would include, strain relief ring <b>400</b> to remove the possibility of the customer pulling out the cable.

For explosion proof installations, the interior <b>380</b> of sensor cartridge <b>350</b> is filled with a potting compound <b>410</b>, such as SYLAST <b>2651</b> with Catalyst #<b>9</b>, for an explosion proof seal. The interior of the end <b>420</b> of sensor cartridge <b>350</b> is filled to face <b>381</b> with a waterproof potting compound from which extends conduit <b>390</b>. End <b>420</b> is threaded by threads <b>430</b> adapted to be attached to a user housing (not shown) containing appropriate electronics.

Threads <b>470</b> terminating at cut back <b>490</b> are formed in interior <b>380</b> of sensor cartridge <b>350</b>. Threads <b>470</b> and cut back <b>490</b> are formed adjacent to end <b>471</b> of the main body portion of sensor cartridge <b>350</b>. The threads <b>471</b> and cut back <b>490</b> should be of sufficient depth to hold the water proof potting compound <b>410</b> in place so that it cannot be forced out, such as around exit conduct <b>390</b> by pressure applied through the process, such as through sheath <b>300</b>.

Detents <b>450</b> are formed in the external portion of the main body of sensor cartridge <b>350</b> to facilitate screwing the body portion of sensor cartridge <b>350</b> into an exterior explosion proof housing (not shown) which may also be explosion proof

Because many varying and different embodiments may be made within the scope of the invention concept taught herein which may involve many modifications in the embodiments herein detailed in accordance with the descriptive requirements of the law, it is to be understood that the details herein are to be interpreted as illustrative and not in a limiting sense.